Constant Velocity Joint: Service and Repair

REPLACEMENT
1. Jack up car and remove wheel
2. Remove large nut holding drive (axle) shaft to wheel bearing housing.





3. Remove bolts and nuts securing top and bottom halves of rear axle member.





4. Remove:
- bolts holding drive (axle) shaft to final drive
- drive (axle) shaft.





5. Remove outer cover from drive (axle) shaft joint Tap off cover carefully with hammer and drift.





6. Carefully tap off inner cover Remove inner clip. Push gaiter over drive (axle) shaft.





7. Remove:
- grease, until circlip is visible
- circlip





8. Press joint off shaft Use drift.
Remove gaiter from drive (axle) shaft and wash shaft clean.
When replacing gaiters only: Remove original gasket from joint. Carefully wash joint clean and rinse with clean washing fluid. Blow joint dry. Check that balls and races of joint are free of damage.
Remove gaiter from inner cover. Wash both covers clean of grease and sealing compound.





9. Install/mount:
- new gaiter and inner cover
- universal





10. Press joint onto drive (axle) shaft Use drift 2731 and universal puller as counterhold.
Install new circlip.





11. Remove protective paper from new gasket. Locate gasket in recess in joint





12. Pack joint and outer cover with grease
Use grease supplied with kit.
13. Press home cover
14. Press new grease into joint and bellows
15. Coat inner cover with sealing agent. Press home cover.
16. Place gaiter in position on cover and on drive (axle) shaft.





17. Install clips and tighten with pincers.





18. Install:
- drive (axle) shaft
- bolts securing shaft to final drive. Use new, oiled bolts. Tighten to 30 Nm (22 ft. lbs.) and angle-tighten through 90 degrees. Alternatively, torque to 65-75 Nm (48-55 ft. lbs.).





19. Insert two M12 bolts or two 12 mm drifts in rear axle member centering holes

NOTE: This is essential to ensure that wheel alignment is correct after assembly.





20. Tighten bolts securing upper and lower halves of rear axle member. Tighten to 70 Nm (52 ft. lbs.) and angle-tighten through 30 degrees.





21. Install:
- large nut holding drive (axle) shaft to wheel bearing housing. Use new, oiled nut.
- wheel and tighten nuts to 85 Nm (63 ft. lbs.).
22. Lower car. Apply hand brake
23. Tighten drive (axle) shaft nut to 140 Nm (103 ft. lbs.) and, then angle-tighten through 60 degrees.